mirror of
git://projects.qi-hardware.com/wernermisc.git
synced 2024-12-23 03:20:49 +02:00
238 lines
9.5 KiB
Plaintext
238 lines
9.5 KiB
Plaintext
--- Thu 2011-09-01 ------------------------------------------------------------
|
|
|
|
PCB milling #1:
|
|
- setup:
|
|
- board is pertinax
|
|
- locally sourced "W.T." (Taiwan) mounting tape
|
|
- measurements:
|
|
- board: 101.6 mm x 44.6 mm (nom. 102.0 mm x 50.0 mm)
|
|
- defects found:
|
|
- drill broke on first hole, due to insufficient clearance found in
|
|
run #2. Second drill just cleared the board by sheer luck.
|
|
- drill/mill depth too shallow
|
|
- column cavities too wide
|
|
- changes for next run:
|
|
- narrow column cavities from 8.4 mm to 8.0 mm (bad idea, see below)
|
|
|
|
PCB milling #2;
|
|
- changes made:
|
|
- board is FR4
|
|
- corrected depth
|
|
- defects found:
|
|
- clearance insufficient (top copper damaged; endmill broke)
|
|
- changes for next run:
|
|
- increase clearance by 1 mm
|
|
- future: include board thickness in gp2rml clearance calculation
|
|
(gp2rml calculates "clearance" from the highest point in the plot,
|
|
which for PCBs also happens to be the lowest point, and thus
|
|
includes the board itself and the vertical overshoot. 2 mm are
|
|
sufficient for 0.8 mm boards, but 1.6 mm boards need at least
|
|
0.8 mm more.)
|
|
|
|
PCB milling #3:
|
|
- changes made:
|
|
- corrected clearance
|
|
- Tesa 5767 mounting tape (no longer available)
|
|
- measurements:
|
|
- column cavity: ~7.6 mm x 10.3 mm (nom. 8.0 x 10.4 mm)
|
|
- board: 102.2 mm x 50.2 mm (nom. 102.0 mm x 50.0 mm)
|
|
- "narrow tongue": 9.1 mm (nom. 9.0 mm)
|
|
- "wide tongue": 14.1 mm (nom. 14.0 mm)
|
|
- defects found:
|
|
- column cavities too narrow (also in design; need 8.4 mm)
|
|
- 100 mil header holes a little bit too small
|
|
- 200 mil header holes much too small
|
|
- rear edge touches wall
|
|
- front edge very close to buttons (not sure how close)
|
|
- changes for next run:
|
|
- widen column cavities by 0.2 mm on each side
|
|
- compensate tool for 0.1 mm of board deflection on each side
|
|
|
|
--- Fri 2011-09-02 ------------------------------------------------------------
|
|
|
|
Layout printed on #3:
|
|
- infrastructure:
|
|
- tried new approach of transferring both sides: instead of stapling
|
|
the two sheets, put adhesive tape around the edges. The result is
|
|
acceptable, but not as good as the work-intensive one side at a time
|
|
approach used for ben-wpan.
|
|
- battery pack for laminator control broke down mechanically. Replaced
|
|
with adapter for obscure 500 mil pack I had laying around.
|
|
- problems found:
|
|
- "make it look like an accident" isn't such a good idea for the trace
|
|
connecting the relays to 5V. I was tempted to scratch off the toner,
|
|
thinking the pin had bled into the trace.
|
|
- annulus around DIP pins seems too small for 35 mil holes. The holes
|
|
are nominally only 0.5 mm, but that in turn may make them too small.
|
|
- changes for next run:
|
|
- make 5V relay traces go clearly for the centers of the respective pins
|
|
- determine correct hole size for DIP
|
|
|
|
--- Sat 2011-09-03 ------------------------------------------------------------
|
|
|
|
Soldered #3:
|
|
- problems found:
|
|
- DIP copper rings were too small for easy soldering, as expected
|
|
- cosmetic: screw-down headers (K1, K2) are very loose and end up
|
|
visibly angled
|
|
- cosmetic: vias between OUT opto-couplers are a bit close to the
|
|
sockets, making them almost disappear under them. Would be nicer if
|
|
they had more clearance.
|
|
- MCU and DIP sockets should have orientation markings on the copper
|
|
layer. In other news, Chip Quick is quite suitable for removing a
|
|
misplaced 32-LQFP.
|
|
- the footprints of the 1 W resistors (R7-R10) are way too short.
|
|
Placed 0805 instead.
|
|
|
|
--- Sun 2011-09-04 ------------------------------------------------------------
|
|
|
|
Milled face plate #0:
|
|
- setup:
|
|
- board is pertinax
|
|
- locally sourced "W.T." (Taiwan) mounting tape
|
|
- measurements:
|
|
- board: 104.0-104.1 mm x 35.1-35.6 mm (nom. 104.0 mm x 35.0 mm)
|
|
- button hole: 12.6-12.8 mm x 11.3-11.6 mm (nom. 12.6 x 11.3 mm)
|
|
- defects found:
|
|
- engraving depth (0.2 mm) is a bit shallow, probably due to board
|
|
curvature
|
|
- got the banana jack diameter wrong: should be 8 mm, not 6 mm
|
|
- button holes show significant deviation from tool path on lower
|
|
edge
|
|
- changes for next run:
|
|
- increase engraving depth to 0.5 mm (board is 1.6 mm)
|
|
- correct banana jack hole diameter
|
|
|
|
Milled face plate #1:
|
|
- changes made:
|
|
- increased engraving depth to 0.5 mm
|
|
- increased banana jack hole diameter to 8.0 mm
|
|
- defects found:
|
|
- job didn't complete because board became unstuck while milling
|
|
- the 8.0 mm hole is still a bit too tight if jack sleeve is at
|
|
upper end of tolerance range
|
|
- noticed that the button holes are milled last, after cutting the
|
|
board outline. This explains the poor accuracy.
|
|
|
|
--- Mon 2011-09-05 ------------------------------------------------------------
|
|
|
|
Milled face plate #2:
|
|
- changes made:
|
|
- board is unclad FR4
|
|
- added a bit more adhesive tape
|
|
- increased banana jack hole diameter from 8.0 mm to 8.1 mm, to
|
|
accommodate also jacks that are at the upper end of the tolerance
|
|
range
|
|
- corrected order of tool paths issues by cameo
|
|
- measurements:
|
|
- board: 104.1-104.2 mm x 35.1 mm (nom. 104.0 mm x 35.0 mm)
|
|
- button hole: 12.5-12.6 mm x 11.3-11.4 mm (nom. 12.6 x 11.3 mm)
|
|
- defects found:
|
|
- tight horizontal fit in the case
|
|
- LED holder have considerable play and retainer rings are loose to
|
|
the point of being useless
|
|
- adhesive tape now sticks almost too well :-) (it was hard to pry
|
|
the board loose after milling)
|
|
|
|
Milled face plate #3:
|
|
- changes made:
|
|
- reduced board width from 104.0 mm to 103.6 mm
|
|
- reduced LED hole from 6.9 mm to 6.2 mm
|
|
- problems encountered:
|
|
- raw board wasn't quite large enough for the entire face plate, but
|
|
it seems I missed it by only < 0.1 mm.
|
|
- depth was too shallow, at the cost of the logo
|
|
- measurements:
|
|
- board: 103.8 mm x 35.1 mm (nom. 103.6 mm x 35.0 mm)
|
|
- defects found:
|
|
- LED holder works better but is still a bit wobbly
|
|
- (EE issue) there's a bit of current from 5 V through the opt-coupler
|
|
LEDs to the pull-ups. Work-around: add 10 kOhm in parallel to each
|
|
LED.
|
|
|
|
--- Wed 2011-09-07 ------------------------------------------------------------
|
|
|
|
Rework:
|
|
- problem: labsw occasionally (around 1% of all cycles in an automated
|
|
test loop) gets some configuration bits wrong. The pattern observed
|
|
so far is that, in an attempt to turn on CH1, then CH2, CH1 comes on
|
|
normally while CH2 either doesn't come on at all or the relay switches
|
|
but the LED doesn't.
|
|
- analysis:
|
|
This may be a problem with the power supply or with USB. Consider
|
|
some or all of the following improvements:
|
|
|
|
- follow SiLab's recommendations for regulator bypassing more closely
|
|
- enable the VDD monitor to catch brown-outs
|
|
- add ground areas to shield CPU and USB
|
|
- add redundancy to EP0 protocol
|
|
- add bead to relay power, to prevent upsetting the 5 V rail
|
|
- rework:
|
|
Implemented power supply bypassing according to SiLabs' recommendations:
|
|
- added 4.7 uF in parallel to C1
|
|
- added 100 nF in parallel to C2
|
|
- results:
|
|
A test run initially showed about 10% abnormal cycles. Detailed
|
|
observation, starting with first anomaly:
|
|
|
|
- turn-on cycle: CH2 LED green, M1 not powered (CH2 fully off ?)
|
|
- 21 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (LEDs didn't go dark as they
|
|
would in DFU wait, so the MCU didn't reset)
|
|
- 8 normal cycles
|
|
- turn-on cycle: MAIN and CH2 LED green, M1 not powered
|
|
- 31 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 12 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 3 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 3 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 3 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 68 normal cycles
|
|
- turn-on cycle: all LEDs green, no power (not a reset)
|
|
- 5+ normal cycles
|
|
|
|
Further analysis: the absence of more abnormal states, such as LEDs
|
|
contradicting relays or LEDs just going dark suggests that the problem
|
|
is may not be USB data corruption. At least some of the symptoms would
|
|
be compatible with EMI from switching the relay creating false signals
|
|
on the buttons.
|
|
|
|
The "all LEDs green" condition would be a false press of MAIN. The
|
|
CH2 green condition would be harder to explain. Maybe the MAIN LED
|
|
was also green and I didn't notice. In this case, it would have been
|
|
a combination of the MAIN and CH1 buttons (MAIN to exit remote mode,
|
|
turn off all the channels, and enable the channel buttons. Then CH1 to
|
|
turn on CH1 again.)
|
|
|
|
To do: debounce buttons (in software) before accepting a state change.
|
|
|
|
---------------------
|
|
|
|
(next PCB run)
|
|
- changes made:
|
|
- made 5V relay traces go clearly for the centers of the respective pins
|
|
- changed DIP hole size from 0.5 mm to 0.8 mm, hole-to-copper ratio from
|
|
2.5 to 2
|
|
- bypass VBUS and VDD with 4.7 uF and 100 nF each
|
|
- added external pull-ups to IN_* and to buttons (so that we can turn
|
|
off the internal pull-ups and thus avoid sneak current through the
|
|
opto-coupler LEDs from VBUS via the pull-ups into VDD)
|
|
- added low-pass filters to button inputs, to suppress interferences,
|
|
e.g., from load being switched (with help from Joerg Reisenweber)
|
|
- added hardware revision ID pins
|
|
- use SPACER-*-BARE for mounting holes without copper
|
|
- updated 2512 footprints (forgot to refresh after editing stdpass.fpd)
|
|
- widened column cavities by 0.2 mm on each side
|
|
|
|
Pending:
|
|
- change mill nominal diameter from 35 mil to 26-27 mil
|
|
- move vias between OUT opto-couplers 0.2 mm to the center
|
|
- add orientation markings on copper layer for MCU and DIP sockets
|
|
- add ground zones
|
|
- firmware: disable internal pull-ups (for hw revision 1)
|
|
- update version (date)
|